US10389103B2 - Breakout boot assemblies and methods for covering electrical cables and connections - Google Patents
Breakout boot assemblies and methods for covering electrical cables and connections Download PDFInfo
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- US10389103B2 US10389103B2 US15/296,157 US201615296157A US10389103B2 US 10389103 B2 US10389103 B2 US 10389103B2 US 201615296157 A US201615296157 A US 201615296157A US 10389103 B2 US10389103 B2 US 10389103B2
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- finger
- main
- expanded
- holdout
- breakout boot
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/08—Cable junctions
- H02G15/18—Cable junctions protected by sleeves, e.g. for communication cable
- H02G15/182—Cable junctions protected by sleeves, e.g. for communication cable held in expanded condition in radial direction prior to installation
- H02G15/1826—Cable junctions protected by sleeves, e.g. for communication cable held in expanded condition in radial direction prior to installation on a removable hollow core, e.g. a tube
- H02G15/1833—Cable junctions protected by sleeves, e.g. for communication cable held in expanded condition in radial direction prior to installation on a removable hollow core, e.g. a tube formed of helically wound strip with adjacent windings, which are removable by applying a pulling force to a strip end
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/08—Cable junctions
- H02G15/18—Cable junctions protected by sleeves, e.g. for communication cable
- H02G15/182—Cable junctions protected by sleeves, e.g. for communication cable held in expanded condition in radial direction prior to installation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/20—Cable fittings for cables filled with or surrounded by gas or oil
- H02G15/24—Cable junctions
Definitions
- the present invention relates to electrical cables and connections and, more particularly, to protective covers for electrical cables and electrical connections.
- a loss of cable integrity for example, a short circuit in a high voltage cable, may result in a crippling power outage or, even worse, a loss of life.
- One everyday task that may pose a great threat to cable integrity is the formation of electrical connections.
- a bare metal surface When electrical connections are formed, a bare metal surface may be exposed such as a splice connector. These bare metal surfaces may be particularly hazardous when formed in the field where they are exposed to the environment. This environment may include rocks and other sharp objects as well as moisture when the connection is to be buried under ground and rainfall when the connection is to be suspended in the air. Thus, there is a need to protect such electrical connections from the environment.
- a pre-expanded breakout boot assembly for protecting a cable joint, the cable joint including a trunk and a plurality of cables extending from the trunk, includes a breakout boot assembly and plurality of removable finger holdouts.
- the breakout boot assembly includes a cold-shrinkable, electrically insulative, elastomeric breakout boot and plurality of finger sealant layers of a conformable medium.
- the breakout boot includes a tubular main section having an interior surface defining a main passage, and a plurality of tubular fingers extending from an end of the main section, each of the fingers having an interior surface defining a finger interior passage.
- Each of the finger sealant layers is pre-mounted on the interior surface of a respective one of the fingers.
- the conformable medium is a flowable material.
- Each of the finger holdouts is mounted in the finger passage of a respective one of the fingers such that the finger holdout maintains the finger in an elastically radially expanded state, and the finger holdout is selectively removable from the finger to permit the finger to elastically radially contract.
- Each finger sealant layer is positioned and configured such that, when the pre-expanded cover assembly is positioned on the cable joint with a cable extending through each finger passage, the finger holdouts are removed from the breakout boot assembly, and each finger elastically radially contracts about a respective one of the cables, each finger sealant layer will be radially interposed between each of the interior surface of the finger and the cable extending through the finger.
- a method of manufacturing a pre-expanded breakout boot assembly for protecting a cable joint, the cable joint including a trunk and a plurality of cables extending from the trunk includes providing a cold-shrinkable, electrically insulative, elastomeric breakout boot and a plurality of removable finger holdouts.
- the breakout boot includes a tubular main section having an interior surface defining a main passage, and a plurality of tubular fingers extending from an end of the main section, each of the fingers having an interior surface defining a finger interior passage.
- the method further includes mounting each of a plurality of tubular finger sealant layers of a conformable medium on a respective one of the plurality of removable finger holdouts, wherein the conformable medium is a flowable material.
- the method further includes thereafter mounting each of the finger holdouts in the finger passage of a respective one of the fingers such that the finger holdout maintains the finger in an elastically radially expanded state, and the finger holdout is selectively removable from the finger to permit the finger to elastically radially contract.
- Each finger sealant layer is positioned and configured such that, when the pre-expanded cover assembly is positioned on the cable joint with a cable extending through each finger passage, the finger holdouts are removed from the breakout boot assembly, and each finger elastically radially contracts about a respective one of the cables, each finger sealant layer will be radially interposed between each of the interior surface of the finger and the cable extending through the finger.
- a method for protecting a cable joint includes providing a pre-expanded breakout boot assembly including a breakout boot assembly and a plurality of removable finger holdouts.
- the a breakout boot assembly includes a cold-shrinkable, electrically insulative, elastomeric breakout boot and a plurality of tubular finger sealant layers of a conformable medium.
- the breakout boot includes a tubular main section having an interior surface defining a main passage, and a plurality of tubular fingers extending from an end of the main section, each of the fingers having an interior surface defining a finger interior passage.
- Each of the finger sealant layers is pre-mounted on the interior surface of a respective one of the fingers.
- the conformable medium is a flowable material.
- Each of the finger holdouts is mounted in the finger passage of a respective one of the fingers such that the finger holdout maintains the finger in an elastically radially expanded state, and the finger holdout is selectively removable from the finger to permit the finger to elastically radially contract.
- the method further includes mounting the pre-expanded breakout boot assembly on the cable joint, including: positioning the pre-expanded breakout boot assembly over the cable joint such that each of the cables extends through a respective one of the finger holdouts and the trunk portion extends through the main section; and removing the finger holdouts from the fingers to permit the fingers to elastically radially contract about the cables such that each finger sealant layer is radially interposed between each of the interior surface of its finger and the cable extending through its finger.
- FIG. 1 is a front perspective view of a pre-expanded breakout boot assembly unit according to embodiments of the present invention.
- FIG. 2 is a rear perspective view of the pre-expanded breakout boot assembly unit of FIG. 1 .
- FIG. 3 is a cross-sectional view of the pre-expanded breakout boot assembly unit of FIG. 1 taken along the line 3 - 3 of FIG. 1 .
- FIG. 4 is a fragmentary, perspective view of the pre-expanded breakout boot assembly unit of FIG. 1 , wherein a finger of a breakout boot thereof is shown in transparency.
- FIGS. 5-8 illustrate methods for forming a covered cable assembly according to embodiments of the invention using the pre-expanded breakout boot assembly unit of FIG. 1 .
- FIG. 9 is a cross-sectional view of the covered cable assembly of FIG. 8 taken along the line 9 - 9 of FIG. 8 .
- FIG. 10 is a rear perspective view of a pre-expanded breakout boot assembly unit according to further embodiments of the present invention.
- FIG. 11 is a cross-sectional view of the pre-expanded breakout boot assembly unit of FIG. 10 taken along the line 11 - 11 of FIG. 10 .
- FIG. 12 is a fragmentary view of a cable for use with the pre-expanded breakout boot assembly unit of FIG. 10 .
- FIG. 13 is a fragmentary view of the pre-expanded breakout boot assembly unit of FIG. 10 installed on the cable of FIG. 12 .
- first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
- spatially relative terms such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90° or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- cold-applied means that the cover or component can be assembled or installed about a substrate (e.g., a cable) without requiring the use of applied heat at the time of installation.
- cold shrink means that the cover or component can be shrunk or contracted about a substrate (e.g., a cable) without requiring the use of applied heat.
- monolithic means an object that is a single, unitary piece formed or composed of a material without joints or seams.
- the pre-expanded breakout boot assembly unit 100 has a lengthwise axis A-A and includes a breakout cover or boot 110 , three finger sealant layers of a flowable, conformable sealant material or medium (hereinafter, “conformable medium” or “mastic”) 140 A, 140 B, 140 C, three finger holdouts 150 A, 150 B, 150 C, and a main holdout 160 .
- the breakout boot 110 and the finger mastic layers 140 A-C together form a breakout boot assembly 101 .
- the pre-expanded breakout boot assembly unit 100 may be used to cover and electrically insulate electrical substrates such as cables and connectors.
- the pre-expanded breakout boot assembly unit 100 may be used to cover an electrical cable joint or a splice between electrical cables and form a protected cable joint, for example.
- FIGS. 8 and 9 show an exemplary protected cable joint 15 .
- a splice connection 12 FIG. 5
- the breakout boot assembly 101 has been installed from the pre-expanded breakout boot assembly unit 100 over or adjacent the splice connection 12 , as discussed in more detail below.
- the breakout boot assembly 101 may be deployed and mounted on the intended substrate from an expanded configuration, state or position (as shown in FIGS. 1-3 ) to a retracted state or position (as shown in FIGS. 8 and 9 ), as discussed in more detail below.
- the cover assembly 101 is a cold shrink cover, meaning that it can be shrunk or retracted about the substrate without requiring the use of applied heat.
- the breakout boot 110 has a lengthwise axis B-B and opposed ends 110 A, 110 B.
- the breakout boot 110 includes a tubular main section 130 , an integral transition wall 137 , and three integral, tubular finger sections or fingers 120 A, 120 B, 120 C.
- the main section 130 extends from the end 110 A to an inner end 130 B at the transition wall 137 .
- Each finger 120 A-C extends from the transition wall 137 to a respective finger free end 125 at the end 110 B.
- the main section 130 is tubular and has an inner surface 136 defining an axially extending main through passage 134 .
- the main through passage 134 communicates with an end opening 132 at the end 110 A.
- Each finger 120 A-C is tubular and has an inner surface 126 defining an axially extending finger through passage 124 .
- Each finger through passage 124 communicates with an end opening 122 at the end 110 B and with the main through passage 134 at the transition wall 137 .
- the breakout boot 110 can be formed of any suitable material. According to some embodiments, the breakout boot 110 is formed of an electrically insulative material. According to some embodiments, the breakout boot 110 is formed of an elastically expandable material. According to some embodiments, the breakout boot 110 is formed of an elastomeric material. According to some embodiments, the breakout boot 110 is formed of ethylene propylene diene monomer (EPDM) rubber. Other suitable materials may include neoprene or other rubber. According to some embodiments, the breakout boot 110 has a Modulus at 100 percent elongation (M100) in the range of from about 0.6 to 1.1 MPa.
- M100 Modulus at 100 percent elongation
- the breakout boot 110 is molded. In some embodiments, the breakout boot 110 is integrally molded. In some embodiments, the breakout boot 110 is monolithic.
- the thickness TC ( FIG. 3 ) of the breakout boot 110 is in the range of from about 2.7 to 3.3 mm.
- the length LC ( FIG. 3 ) of the breakout boot 110 is in the range of from about 129 to 131 mm.
- the length LF ( FIG. 3 ) of each finger 120 A-C is in the range of from about 88 to 92 mm.
- the length LT ( FIG. 3 ) of the main section 130 is in the range of from about 105 to 135 mm.
- Each of the finger sealant layers 140 A, 140 B, 140 C is a generally cylindrical, tubular layer of a flowable, conformable material or medium (“the conformable medium”). According to some embodiments and as discussed herein, the conformable medium of the layers 140 A, 140 B, 140 C is a conformable, flowable mastic.
- Each mastic layer 140 A-C has an inner surface 143 A ( FIG. 3 ) and an opposing outer surface 143 B, and opposed axial terminal ends 141 A, 141 B.
- Each inner surface 143 A defines an axially extending mastic through passage 144 that communicates with opposed end openings 142 .
- Each of the mastic layers 140 A-C is adhered or bonded by its outer surface to the inner surface 126 of it associated finger 120 A-C.
- Each mastic layer 140 A-C extends continuously from axial terminal end 141 A to axial terminal end 141 B.
- the mastic layers 140 A, 140 B, 140 C may be any suitable type of mastic having the necessary or desired properties to function as intended.
- the mastic layers 140 A, 140 B, 140 C should be sufficiently soft, at temperatures in the intended cold-applied installation and use temperature range, that they can conform to surfaces of the cables 50 A-C as discussed below.
- the mastic layers 140 A-C are electrically insulating.
- the mastic layers 140 A-C have a dielectric constant of at least 100 kV/cm.
- the mastic layers 140 A-C have a volume resistivity of at least 1 ⁇ 10 13 Ohm-cm.
- the mastic layers 140 A-C have a dielectric strength of less than 5.0 Volts/mil.
- the mastic layers 140 A-C have a density in the range of from about 1.45 to 1.55 g/cm 3 .
- each mastic layer 140 A-C has a thickness TM ( FIG. 3 ) in the pre-expanded unit 101 in the range of from about 2 to 4 mm.
- each mastic layer 140 A-C has a length LM ( FIG. 3 ) in the pre-expanded unit 100 in the range of from about 19 to 31 mm.
- Each mastic layer 140 A-C is axially inset from the opposed distal (free) end and proximal (base) end of its finger 120 A-C.
- the inset distance D 1 ( FIG. 3 ) from the free end 110 B is in the range of from about 19 to 26 mm.
- the inset distance D 2 ( FIG. 3 ) from the transition wall 137 is in the range of from about 25 to 39 mm.
- the mastic layers 140 A-C may be formed of any suitable flowable sealing mastic.
- the mastic layers 140 A-C include a polymer that is at least partially crosslinked (semi-crosslinked). While mastic layers 140 A-C include a polymer that is at least partially crosslinked, the mastic layers 140 A-C are still deformable and adherent to the material of the breakout boot 110 and the cable insulation 56 . However, the crosslinking in the mastic layers 140 A-C prevents them from flowing from the breakout boot 110 at operating temperatures. According to some embodiments, the mastic layers 140 A-C are not free flowing at least in an operating temperature range of from ⁇ 20 to 135° C.
- the polymer in the mastic layers 140 A-C has a free flowing temperature that is higher than 140° C., more preferably higher than 150° C., and more preferably higher than 180° C.
- the polymer of the mastic layers 140 A-C does not flow prior to decomposition due to crosslinking.
- mastic layers 140 A-C include crosslinked butyl rubber.
- Other suitable mastics may include mastics including synthetic rubber or synthetic polymer mastics.
- the mastic 140 A-C is a silicone rubber-based mastic. Suitable polymers that may be included in the mastic layers 140 A-C include S1278 sold by TE Connectivity.
- Each finger holdout 150 A-C is a generally cylindrical, tubular member extending from an end 151 A to an end 151 B. Each finger holdout 150 A-C defines a through passage 154 . The passage 154 communicates with opposed end openings 152 .
- each finger holdout 150 A-C includes a flexible strip 155 helically wound to form a rigid cylinder and having a pull tab or end segment 155 A extending through the passage 154 as illustrated, for example.
- the holdouts 150 A-C can be formed of any suitable material. According to some embodiments, the holdouts 150 A-C are formed of a semi-rigid polymeric material. According to some embodiments, the holdouts 150 A-C are formed of polypropylene, ABS, or PVC.
- Each finger holdout 150 A-C has an outer surface 157 .
- Each of the mastic layers 140 A-C is adhered or bonded by its inner surface to the outer surface 157 of it associated finger holdout 150 A-C.
- the main holdout 160 is a generally cylindrical, tubular member extending from an end 161 A to an end 161 B.
- the main holdout 160 has an outer surface 167 and defines a through passage 164 .
- the passage 164 communicates with opposed end openings 162 .
- the main holdout 160 includes a core or body 166 and an elongate rail 168 .
- the rail 168 is seated in an axially extending slot 166 A defined in the body 166 .
- the rail 168 holds the opposed edges of the slot 166 A apart and thereby maintains the rigid, tubular configuration of the holdout 160 .
- the rail 168 can be axially slid out of the slot 166 A to thereby permit the body to collapse radially inwardly.
- each holdout 150 A-C, 160 has a thickness TH ( FIG. 3 ) in the range of from about 3 to 7 mm.
- the thicknesses of the holdouts 150 A-C, 160 may be different from one another.
- the breakout boot assembly 101 and the pre-expanded unit 100 may be formed by any suitable method and apparatus.
- the mastic layers 140 A-C are pre-mounted on the outer surfaces 157 of the finger holdouts 150 A-C, and the fingers 120 A-C are thereafter expanded, placed around the finger holdouts 150 A-C and the mastic layers 140 A-C, and permitted to contract about the finger holdouts 150 A-C and the mastic layers 140 A-C.
- the fingers 120 A-C may be expanded using a sock expander, for example.
- each finger 120 A-C When mounted on its finger holdout 150 A-C, each finger 120 A-C is maintained in an elastically radially expanded state or position. According to some embodiment, in the expanded state each finger 120 A-C is expanded in the range of from about 400 to 200 percent of its relaxed diameter. As a result, the finger 120 A-C of the pre-expanded unit 100 will exert a radially compressive pressure or load on the underlying mastic layer 140 A-C (which is constrained on its interior side by the rigid finger holdout 150 A-C). According to some embodiments, in spite of this compressive loading, the underlying mastic layer 140 A-C will retain its general shape and position and will resist bleed out of oil.
- the main holdout device 160 is assembled by inserting the rail 168 into the slot 166 A.
- the holdout 160 is mounted in the inner passage 134 of the breakout boot 110 such that the main section 130 of the breakout boot 110 is in a radially expanded condition or state as compared to its relaxed state and its intended installed state.
- the elastically expanded main section 130 applies a persistent radially compressive load (i.e., a recovery force) on the holdout 160 , and the holdout 160 resists radial collapse of the body 166 due to this load.
- the holdout 160 thereby serves as a supporting structure that resists radial contraction of the main section 130 .
- the pre-expanded breakout boot assembly 100 may be stored, transported, etc. in this condition.
- FIGS. 5-9 illustrate steps for forming an exemplary protected cable joint 15 .
- methods for using pre-expanded breakout boot assemblies as disclosed herein are not limited to installation on splice connections or cables of a particular type (e.g., polymer insulated cables or PILC cables).
- the cables 40 , 50 A-C are medium-voltage (e.g., between about 5 and 35 kV) or high-voltage (e.g., between about 46 and 230 kV) power transmission cables.
- medium-voltage e.g., between about 5 and 35 kV
- high-voltage e.g., between about 46 and 230 kV
- the cable 40 is a paper insulated lead covered (PILC) cable including three cable cores 42 .
- Each cable core 42 includes an electrical conductor 44 , an oil-impregnated paper insulation layer 46 surrounding the conductor 44 , and a metal (e.g., lead or aluminum) sheath surrounding the cable cores 42 , collectively.
- PILC paper insulated lead covered
- the polymer insulated cables 50 A-C may each include an electrical conductor 54 , a polymeric insulation layer 56 surrounding the conductor 54 , and a polymeric jacket 58 surrounding the polymeric insulation layer 56 .
- Each cable 50 A-C may include additional layers or components including a metal shield layer 57 and a semiconductive layer 59 , for example.
- the cables 50 A-C are concentric neutral cables.
- the cables 50 A-C are metal tape shielded or longitudinally corrugated (LC) metal shielded cables.
- the conductors 54 may be formed of any suitable electrically conductive materials such as copper (solid or stranded).
- the polymeric insulation layers 56 may be formed of any suitable electrically insulative material such as crosslinked polyethylene (XLPE) or EPR.
- the semiconductor layers 59 may be formed of any suitable semiconductor material such as carbon black with silicone.
- the shield layers 57 may be formed of any suitable material such as copper.
- the jacket 58 may be formed of any suitable material such as EPDM rubber or PVC.
- Each conductor 44 is electrically and mechanically connected to the conductor 54 of a corresponding cable 50 A-C using a connector 30 to form an electrical splice between the connected cables.
- a connector 30 to form an electrical splice between the connected cables.
- FIG. 5 only one connector is shown; however, in this step each of the three sets of conductors 44 , 54 are connected.
- the pre-expanded breakout boot assembly 100 Prior to connecting the conductors 44 , 54 , the pre-expanded breakout boot assembly 100 is slid over the cables 50 A-C such that the end opening 132 faces the PILC cable 40 , as shown in FIG. 6 .
- the pre-expanded breakout boot assembly 100 is not shown in the fragmentary view of FIG. 5 .
- various additional components may be installed on the cable 40 and/or the cables 50 A-C to enhance safety, electrical performance, durability, and/or containment of oil from the cable 40 .
- Such components and methods of preparing the cables and splice may include those disclosed in U.S. Pat. No. 8,324,502 to Kameda et al., the disclosure of which is incorporated herein by reference.
- FIG. 6 illustrates the cables 40 , 50 spliced and wrapped with a metal shield mesh wrap 32 .
- the mesh wrap 32 extends from the lead sheath 48 to an end 32 A at or overlapping the jackets 58 of the cables 50 A-C.
- the mesh wrap 32 thereby effectively forms a trunk portion 20 from which the individual cables 40 , 50 extend or fan out at a cable joint 22 .
- the pre-expanded breakout boot assembly 100 is parked on the cables 50 A-C adjacent the splice 12 .
- the pre-expanded unit 100 is slid over one of the cables 50 A-C in the direction I toward the cable 40 until the main section 130 surrounds the trunk portion 20 (i.e., the mesh wrap 32 ).
- the pre-expanded unit 100 is slid onto the mesh wrap 32 until the end wall 137 abuts or is positioned closely adjacent the crotches 24 ( FIG. 6 ) defined between the cables 50 A-C at the end opening of the mesh wrap 32 .
- each finger holdout 150 A-C is greater than the outer diameter of each cable 50 A-C such that the inner diameters of the holdouts 150 A-C are sufficient to slide the pre-expanded unit 100 without undue effort.
- the inside diameter of the main holdout 160 is greater than the outer diameter of the mesh wrap 32 such that the inner diameter of the main holdout 160 is sufficient to receive the mesh wrap 32 without undue effort.
- the inner diameters of the holdouts 150 A-C, 160 are at least as great as the outer diameter of the largest substrates (e.g., cable jackets 58 , mesh wrap 32 ) that are to be received in the breakout boot assembly 102 .
- the rail 168 of the main holdout 160 is then removed from the pre-expanded unit 100 , thereby permitting the body 166 coil up into itself and shrink (radially and circumferentially) in place under the radially compressive load of the elastically expanded main section 130 .
- the main section 130 is thereby permitted to relax and radially retract about the cables 50 A-C and the trunk portion 20 (i.e., the mesh wrap 32 ), as shown in FIG. 8 .
- the relaxed inner diameter of the main section 130 is less than at least the outer diameter of the mesh wrap 32 and the collapsed body 166 . Therefore, the main section 130 exerts a radially inwardly compressive or clamping force or pressure (due to elastic tension) onto the cables 50 and the mesh wrap 32 . It will be appreciated that in this embodiment, the body 166 will remain in the protected cable joint 15 .
- Each finger holdout 150 A-C is then removed from the pre-expanded unit 100 , thereby permitting each finger 120 A-C to relax and radially retract about the cable 50 therein, as shown in FIGS. 8 and 9 .
- the relaxed inner diameter of each finger 120 A-C is less than at least the outer diameter of the cable jacket 58 . Therefore, the finger 120 A-C exerts a radially inwardly compressive or clamping force or pressure (due to elastic tension) about and onto the cable jacket 58 .
- the finger 120 A-C may thereby effect a liquid tight seal at the interfaces between the fingers 120 A-C and the cable jackets 58 . These seals can protect the cable and the splice from the ingress of environmental moisture.
- Each mastic layer 140 A-C preferentially adheres to the inner surface 126 of its finger 120 A-C and separates or releases from the finger holdout strip 155 .
- the mastic layer 140 A-C is thus captured, interposed or sandwiched between the finger 120 A-C and the cable jacket 58 and directly engages the interface surfaces of the cable 50 A-C and the finger 120 A-C as shown in FIG. 9 .
- the finger 120 A-C is not fully recovered to its relaxed state, and therefore continues to apply a persistent radially compressive load or pressure to the mastic layer 140 A-C.
- each finger 120 A-C is less than at least the outer diameter of the jacket layer 58 it surrounds. Therefore, the finger 120 A-C exerts a radially inwardly compressive or clamping force or pressure (due to elastic tension) about and onto the cable 50 A-C. The finger 120 A-C may thereby effect a liquid tight seal at the cable and finger interfaces. These seals can protect the cable and the splice from the ingress of environmental moisture.
- the cover assembly 100 is thereby fully installed to form the protected cable breakout joint 15 as shown in FIGS. 8 and 9 .
- the breakout boot assembly 102 and the splice connection 12 are relatively arranged and configured such that each mastic layer 140 A-C forms an axially and circumferentially continuous tube surrounding its cable 50 through a length LMM ( FIG. 8 ) within the finger 120 A-C.
- Each mastic layer 140 A-C is thus interposed between and engages the interface surfaces of the cable 50 A-C and the finger 120 A-C.
- each mastic layer 140 A-C has a length LMM (when installed; FIG. 8 ) in the range of from about 1 to 1.5 inches.
- each mastic layer 140 A-C when installed, has a thickness TMM ( FIG. 9 ) in the range of from about 3 to 6 mm.
- the pre-expanded unit 101 can provide significant advantages during installation and in service.
- the mastic layers 140 A-C can flow at temperatures in the intended service range, including at room temperature.
- the mastic layers 140 A-C can flow (i.e., are flowable), but are not free flowing, at least at temperatures in an operating temperature range of from about ⁇ 20° C. to 135° C.
- the mastic layers 140 A-C have a free flowing temperature that is higher than 150° C. As such, the cover assembly 100 can be effectively and reliably cold-applied to the splice.
- the mastic layers 140 A-C applied and retained under the elastic pressure of the partially radially expanded breakout boot 110 will flow and conform to the irregularities of the exposed surfaces of the cables 50 A-C and the inner surfaces 126 of the breakout boot fingers 120 A-C.
- the mastic layers 140 A-C can be factory-applied to the breakout boot 110 (to form the breakout boot assembly 102 ) and factory-mounted on the holdouts 150 A-C, 160 (to form the pre-expanded unit 100 or a part thereof. As such, the risks that an installer may forget to apply the mastics or that the mastics may be contaminated are eliminated.
- the factory-applied mastic also eliminates or reduces the risk that the finger mastics will be misapplied (e.g., in the wrong locations or with insufficient or irregular or incomplete coverage).
- the factory-applied mastic may also eliminate the need for separate application of mastics and void filling greases during the product installation process as may be required for known products and installation methods.
- the mastic layers 140 A-C are formulated to be stable under the elastic compression force of the breakout boot 110 while expanded on the holdouts 150 A-C.
- the mastic layers 140 A-C are resistant to oil bleed out under pressure and do not migrate in between the interstices of the holdouts 150 A-C.
- a pre-expanded breakout boot assembly unit 200 (also referred to herein as “the pre-expanded unit 200 ”) according to further embodiments of the present invention is shown therein.
- the pre-expanded unit 200 is constructed in and can be used in the same manner as the pre-expanded unit 100 , except as discussed below.
- the pre-expanded unit 200 includes a includes a breakout cover or boot 210 , three finger sealant layers of a flowable, conformable material or medium (hereinafter, “conformable medium” or “mastic”) 240 A-C, three finger holdouts 250 A-C corresponding to the components 110 , 140 A-C, and 150 A-C, respectively.
- conformable medium hereinafter, “conformable medium” or “mastic”
- the pre-expanded unit 200 further includes a main or trunk section sealant layer 270 of a flowable, conformable sealant material or medium and a main or trunk holdout 260 .
- the breakout boot 210 , the layers 240 A-C, and the main sealant layer 270 form a breakout boot assembly 201 .
- the main holdout 260 is placed and generally functions in the same manner as the holdout 160 .
- the main holdout 260 is a spirally wound holdout of the same construction as described above the finger holdouts 150 A-C.
- the main holdout 260 includes a helically wound strip 265 having a pull section 265 A.
- the main or trunk sealant layer 270 of a flowable, conformable sealant material or medium may be a layer of mastic as described above for the layers 140 A-C.
- the medium or mastic of the layer 270 may be the same or different in composition, properties and/or dimensions as the layers 240 A-C.
- the breakout boot assembly 201 may be installed from the pre-expanded unit 200 in the same manner as described above for the pre-expanded unit 100 . However, in the case of the pre-expanded unit 200 , the body of the holdout 260 is removed from the breakout boot 210 and, when installed, the trunk mastic layer 270 is interposed between the main section 230 and the underlying substrate (e.g., the mesh wrap 32 ). The trunk mastic layer 270 will engage the inner surface of main section 230 and the outer surface of the substrate.
- the cable 61 includes a bundle of three cores 60 surrounded by a tubular, electrically insulating cable jacket 69 .
- Each core 60 includes a conductor 64 surrounded by a respective insulation layer 66 and jacket 68 .
- the cores 60 may each be a polymer insulated cable or an insulated wire, for example.
- the cable 61 is prepared as show in FIG. 12 such that sections of the cores 60 extend axially outwardly beyond an open end 68 A of the jacket 68 at a joint 22 ′.
- the pre-expanded unit 200 mounted on the cable 61 such that the cores 60 extend through the finger holdouts 250 A-C.
- the pre-expanded unit 200 is then slid over the jacket 68 adjacent the joint 22 ′.
- the holdouts 250 A-C are removed from the fingers 220 A-C and the main section 230 .
- the breakout boot assembly 201 is thereby installed on the cable 61 with the finger mastic layers 250 A-C interposed between and contacting each of the inner surface of the associated finger 220 A-C and the outer surface of the core insulation or jacket 68 .
- the holdout 260 is removed from the main section 230 .
- the breakout boot assembly 201 is thereby installed on the cable jacket 69 with the main section mastic layer 270 interposed between and contacting the inner surface of the main section 230 and the outer surface of the cable jacket 69 .
- the cable 61 may be a PILC cable, in which case the component 69 would be a metal sheath and the cores 60 would be paper insulated conductors.
- Pre-expanded breakout boot assemblies can be used to cover and seal any suitable cable joint.
- the trunk portion may be, but is not limited to, a jacketed bundle of cables from which individual cables or cores extend or fan out (e.g., as shown in FIG. 12 ), one or more splices from which individual cables or cores extend or fan out (e.g., as shown in FIG. 5 ), or a bundle of cables that are re-jacketed or otherwise covered with individual cables or cores extending or fanned out from the re-jacket or other cover.
- the outermost layer of the trunk portion may be, for example, an original cable jacket, a re-jacket or other cover, a metal shield layer (e.g., a metal mesh wrap), a metal sheath (e.g., a lead sheath of a PILC cable), an oil barrier tube, or any other suitable component.
- a metal shield layer e.g., a metal mesh wrap
- a metal sheath e.g., a lead sheath of a PILC cable
- oil barrier tube e.g., oil barrier tube, or any other suitable component.
- the pre-expanded breakout boot assembly may include a collapsible main holdout that remains in the joint when the breakout boot assembly is installed (e.g., as in FIG. 8 ), a removable main holdout that is removed to permit a trunk mastic to remain in the installed breakout boot assembly (e.g., as in FIG. 13 ), or a removable main holdout that is removed without provision of a trunk mastic.
- finger sealants 140 A-C, 240 A-C are shown and described herein installed such that they engage the outer surfaces of the cable jackets 58 , 68
- the installed finger sealants may engage (i.e., contact) a different layer of the cable 50 A-C, 60 or a layer surrounding the cable 50 A-C, 60 (e.g., an oil barrier tube or re-jacketing sleeve).
- the main section sealant layer 270 may engage a different layer of the trunk or a layer surrounding the trunk (e.g., superimposed over the jacket 69 ; e.g., an oil barrier tube or re-jacketing sleeve).
- pre-expanded breakout boot assembly units as disclosed herein can make installation of a breakout boot with sealant layers easier and less time-consuming.
- the inventive pre-expanded breakout boot assembly units can reduce the finger strength and dexterity required of the installer.
Landscapes
- Cable Accessories (AREA)
Abstract
Description
Claims (10)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US15/296,157 US10389103B2 (en) | 2016-10-18 | 2016-10-18 | Breakout boot assemblies and methods for covering electrical cables and connections |
PCT/US2017/054365 WO2018075222A1 (en) | 2016-10-18 | 2017-09-29 | Breakout boot assemblies and methods for covering electrical cables and connections |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US15/296,157 US10389103B2 (en) | 2016-10-18 | 2016-10-18 | Breakout boot assemblies and methods for covering electrical cables and connections |
Publications (2)
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US20180109100A1 US20180109100A1 (en) | 2018-04-19 |
US10389103B2 true US10389103B2 (en) | 2019-08-20 |
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US15/296,157 Active 2037-02-10 US10389103B2 (en) | 2016-10-18 | 2016-10-18 | Breakout boot assemblies and methods for covering electrical cables and connections |
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WO (1) | WO2018075222A1 (en) |
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CN115693585B (en) * | 2022-12-30 | 2023-03-10 | 义博通信设备集团股份有限公司 | Multifunctional cold-shrinking multi-finger sleeve convenient to operate |
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